Got the new motor and cage for the upgrade but can't get the heater to operate. The motor s end like it is grounded by the housing. I have a ground wire coming off but it still won't work. Did I get the right motor or am I just not grounding it right?

I'd bench test the motor, I guess. Sounds right to me. I used the parts listed in this thread (maybe a different brand, but crossreferenced to the same vehicle, I forget), and added a ground wire from the motor to the metal part of the heater housing. Seemed to ground fine with the heater housing bolted to the firewall.

http://www.classicbroncos.com/forums/sh ... ostcount=6

X2 I made a ground the same way. works good!

Bench tested and works well. When installed in truck it pops the fuse because it doesn't seem like it's ground d well enough . Any thoughts.

A popping fuse will be a power short to ground or circuit overload. Check your wiring and make sure your cage is free inside the boxö

My heater fuse (in the original fuse box) was actually melting the solder inside the fuse itself. The tabs that held the fuse in place were rusty, and I cleaned them up with some sand paper & everything started working fine again.

Do you have a similar sized fuse on the bench test? That would eliminate the fan itself as the problem.

So the cage was hitting the metal housing on the back and grounding out. Has anyone had to make a spacer plate between the motor and th housing. I cross referenced all the parts and they seem correct. What do you all think?

It's been a long time since I did this but I seem to remember that the fan had to be clocked to a specific location, or there was a problem. This might not be the same thing you have happening. It's just been to long ago for me to remember the specifics.

I also remember that I had to clock or move the motor slightly in the housing. I will be doing this on the 72 here soon so will refresh my memory.

Had a buddy with a 3d printer make a small spacer between the housing and the motor to clearance the cage. Should work like a charm now. Got my reseal kit for Christmas so just need to do that and should be golden.

The core seems good but do you all think I should replace?